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Mesin Keseluruhan Kelengkapan Mesin Mekanisme Katup Sistem Pendinginan Sistem Intake dan Exhaust Sistem Bahan Bakar Sistem Pengapian Sistem Serpentine Belt Drive Engine Control System

Mesin Keseluruhan Garis Besar Mesin 1TR-FE leaded gasoline, merupakan rancangan baru in-line 4-cyliner, 2.0-liter, 16-valve DOHC dengan VVT-i, chain drive [Engine Feature] In-line type, 4-cylinder, 2.0-litter, 16-vale DOHC with VVT-i, chain drive leaded gasoline engine. Equipment: DIS, ETCS-i

Mesin Keseluruhan Spesifikasi Mesin Model 1TR-FE 1RZ-E (KIJANG) Jumlah silinder & susunan 4-cylinder, In-line  Mekanisme Katup 16-valve, DOHC with VVT-i, Chain Drive 8-valve, SOHC, Chain Drive Displacement [cm3 (cu. in.)] 1998 (121.9) Bore x Stroke [mm (in.)] 86.0 x 86.0 (3.39 x 3.39) Compression Ratio 9.8 : 1 9.0 : 1 Maximum Output SAE-NET [kW / rpm] 100 / 5,600 71 / 4,800 Maximum Torque SAE-NET [N·m / rpm] 182 / 4,000 152 / 2,800 Valve Timing Intake Buka 0  45 BTDC 13 BTDC Tutup 64  19 ABDC 47 ABDC Exhaust 44 BBDC 53 BBDC 8 ATDC 7 ATDC Fuel Octane Rating 91 atau lebih Oil Viscosity / Oil Grade 5W-30 / API SL, SJ, EC or ILSAC [Other Spesifikasi] Combustion Chamber: Pentroof Type Manifolds: Cross-flow Sistem Bahan Bakar: EFI Sistem Pengapian: DIS Firing Order: 1-3-4-2 Fuel: Leaded Gasoline

Mesin Keseluruhan Keseluruhan DIS and Long Reach Type Spark Plug Long Nozzle 4-hole Type Injector Resin Type Cylinder Head Cover Stainless Steel Exhaust Manifold Flat type knock sensor Segment Conductor Type Alternator No-contact Type Throttle Position Sensor [1TR-FE Mesin Keseluruhan] Resin type cylinder head cover Resin type intake manifold Stainless steel exhaust manifold Long nozzle 4-hole type injector TOYOTA genuine super LLC Segment conductor type alternator DIS and long reach type spark plug No-contact type throttle position sensor Flat type knock sensor VVT-i system VVT-i System Resin Type Intake Manifold TOYOTA Genuine Super LLC

Mesin Keseluruhan Informasi Identifikasi Nomor mesin di cetak pada sisi kiri bawah blok mesin

Kelengkapan Mesin Tutup Kepala Silinder Mengurangi konsumsi oli mesin yang melalui blow-by gas, berat dan juga suaranya Ke Intake Manifold Resin Fresh Air The baffle plates are welded onto the cylinder head cover, and cannot be removed. The resin type cylinder head cover Acrylic Rubber Baffle Plate

Hydraulic Lash Adjuster Kelengkapan Mesin Kepala Silinder Terbuat dari aluminum alloy ringan 22.85° Hydraulic Lash Adjuster Aluminum Alloy Aluminum alloy cylinder head for light weight Three-layer laminated cylinder head gasket for higher sealing performance and durability Hydraulic lash adjuster for maintenance free Narrower angle of valves for better combustion 3-layer Steel Laminate Taper Squish

Kelengkapan Mesin Blok Silinder Terbuat dari cast iron, memiliki sirip untuk memperkuat rigiditas dan mengurangi suara dan getaran Cast Iron Cast iron cylinder block with rib for lower noise and vibration Aluminum alloy No. 1 oil pan for light weight and higher rigidity Aluminum Alloy Steel

Kelengkapan Mesin Piston Dari bahan aluminum alloy, menggunakan ring piston low tension untuk mengurangi keausan Taper Squish Shape Alumite Treatment for Top Ring Groove [Low Tension Piston Rings] 2 Pieces Oil Ring Chrome-plated 2nd Compression Ring PVD Coated 1st Compression Ring Alumite treated top piston ring groove for higher durability Low tension piston ring for lesser friction Resin Coating PVD: Physical Vapor Deposition

Kelengkapan Mesin Bearing Crankshaft Bearing crankshaft yang tak memiliki kuku (claw) Permukaan bearing micro-grooved (alur halus) [Bearing Atas] [Bearing Bawah] No more bearing claw for both upper and lower bearing Micro-grooved

Service Point (Kelengkapan Mesin) Pemasangan Ring Piston Set Tempatkan ring piston hingga ujung nya seperti pada gambar dibawah Expander 45° No. 2 Compression Oil Ring No. 1 Compression [Piston ring end positioning] No. 1: Match the piston front mark No. 2: Opposite side of No. 1 piston ring end Expander: Between 90 degrees and 45 degrees from No. 1 piston ring end Oil ring: Same as No. 1 piston ring end *Stamped side will be in upward Front Mark

Service Point (Kelengkapan Mesin) Pemasangan Bearing Crankshaft Bagian Atas Posisi bearing harus berada di tengah journal blok silinder untuk meluruskan lubangnya [Upper Bearing] [OK] Center Lubrication Hole Mono size of crankshaft bearing Bearing position should be centered to the cylinder block journal to align the oil hole [NG] Lubrication Hole

Service Point (Kelengkapan Mesin) Pemasangan Bearing Crankshaft Bagian Bawah Bearing harus berada di tengah, ukur posisinya [Perbedaan antara “B” dan “C”: 0.3 mm (0.012 in.) atau kurang] B C Vernier Caliper Bearing should be positioned in center and measure the position Difference between B and C is 0.3 mm (0.012 in.) or less

Service Point (Kelengkapan Mesin) Pemasangan Bearing Crankshaft Nilai Referensi A B A C Vernier Caliper Journal Bearing Atas Bearing Bawah Ukuran “A” [mm (in.)] Ukuran “B” atau “C” [mm (in.)] #1, 5 3.75 (0.1476 )  0.1 (0.004) 3.83 (0.1508)  0.1 (0.004) #3 1.75 (0.0689 in.)  0.1 (0.004) 1.74 (0.0689)  0.1 (0.004) #2, 4 2.75 (0.0183)  0.1 (0.004)

Service Point (Kelengkapan Mesin) Baut Puli Crankshaft Baut puli crankshaft tak boleh digunakan kembali Crankshaft set bolt is non-resusable parts. Special treatment is applied onto the surface of bolt tread to ensure the accurate tightening torque. If it is used once, this surface will be degraded. Crankshaft Pulley Set Bolt

Mekanisme Katup Keseluruhan Mekanisme Katup Terdiri dari roller rocker arm, hydraulic lash adjuster dan sistem VVT-i Oil Delivery Pipe (cam dan rocker arm) Roller Rocker Arm Exhaust Valve Oil delivery pipe for improvement of lubrication on cam face Hydraulic lash adjuster for minimizing valve clearance VVT-I on all destination of Mesin 1TR-FE Timing Chain: High-strength roller chain with a 9.525 mm pitch (120 links) On the leaded gasoline engine, the valve faces of the intake and exhaust valve have been metallized to improve their wear resistance. Hydraulic Lash Adjuster Intake Valve Timing Chain VVT-i Controller

Mekanisme Katup Rocker Arm Roller rocker arm dengan built-in needle bearing digunakan untuk mengurangi gesekan, sehingga memperbaiki konsumsi bahan bakar Oil Delivery Pipe [Roller Rocker Arm] Needle Bearing Roller Rocker Arm

Mekanisme Katup Hydraulic Lash Adjuster Mempertahankan celah katup nol dengan menggunakan tekanan oli dan tegangan pegas Plunger Low Pressure Chamber Zero Valve Clearance Oil Passage Check Ball The hydraulic lash adjuster, which is located at the fulcrum of the roller rocker arm, consists of plunger, plunger spring , check ball and check ball spring. Oil in chamber is stored and it decrease the clearance Check Ball Spring High Pressure Chamber Plunger Spring Oil Passage

Reference (Mekanisme Katup) Roller Rocker Arm dan Hydraulic Lash Adjuster Oil Passage Oil Passage

Mekanisme Katup Hydraulic Lash Adjuster Awal penekanan katup, tekanan tinggi dari high pressure chamber didapat dari tekanan plunger Plunger High Pressure Chamber

Mekanisme Katup Hydraulic Lash Adjuster Kemudian rocker arm membuka katup dengan menggunakan hydraulic lash adjuster sebagai tumpuan Fixed Plunger Tumpuan High Pressure Chamber

Mekanisme Katup Hydraulic Lash Adjuster Cam naik, plunger diangkat oleh plunger spring, check valve terbuka, dan oli terisi. Body Plunger Check Ball High Pressure Chamber

Mekanisme Katup Hydraulic Lash Adjuster Plunger diangkat oleh tekanan pegas. Sehingga celah katup tetap nol Zero Valve Clearance Plunger Plunger Spring

Mekanisme Katup Hydraulic Lash Adjuster Cara Kerja

Service Point (Mekanisme Katup) Hydraulic Lash Adjuster Prosedur penggantian oli 1. Tekan check ball ke bawah dengan SST SST [SST: 09276-75010] Charge the clean engine oil to hydraulic lash adjuster, when the hydraulic lash adjuster relation parts are disassembled [Caution at Installation for Hydraulic lash Adjuster] Keep the hydraulic lash adjuster free from dirt and foreign objects Only use clean engine oil when engine oil is recharged DO NOT disassemble Hydraulic Lash Adjuster Benar Salah

Service Point (Mekanisme Katup) Hydraulic Lash Adjuster Prosedur penggantian oli 2. Masukkan hydraulic lash adjuster pada oli mesin bersih, tekan adjuster dengan SST untuk menggerakan plunger naik turun 5 - 6 kali Clean Engine Oil Charge the clean engine oil to hydraulic lash adjuster, when the hydraulic lash adjuster relation parts are disassembled [Caution at Installation for Hydraulic lash Adjuster] Keep the hydraulic lash adjuster free from dirt and foreign objects Only use clean engine oil when engine oil is charged Basically, DO NOT disassemble If the hydraulic lash adjuster is disassembled, combination of each part should not be changed (Body, plunger, check ball retainer, check ball)

Service Point (Mekanisme Katup) Hydraulic Lash Adjuster Prosedur penggatian oli 3. Plunger akan keras ketika plunger ditekan kuat dengan tangan Charge the clean engine oil to hydraulic lash adjuster, when the hydraulic lash adjuster relation parts are disassembled [Caution at Installation for Hydraulic lash Adjuster] Keep the hydraulic lash adjuster free from dirt and foreign objects Only use clean engine oil when engine oil is charged Basically, DO NOT disassemble If the hydraulic lash adjuster is disassembled, combination of each part should not be changed (Body, plunger, check ball retainer, check ball)

Service Point (Mekanisme Katup) Hydraulic Lash Adjuster Prosedur penggantian oli Ganti dengan yang baru, jika plunger bisa bergerak walau olinya sudah diganti 3 kali

Service Point (Mekanisme Katup) Timing Chain Pasang rantai pada sprockets dengan bagian yang dicat lurus terhadap tanda timing Yellow Paint Yellow Paint Timing mark Orange Paint Chain Tensioner Key Crankshaft: No1. TDC Timing mark

Sistem Pendinginan Pendingin Mesin Tipe pendingin mesin TOYOTA Genuine Super Long Life Coolant (SLLC) atau sejenis Kapasitas [liters (US qts, Imp. qts)] 7.0 (7.4, 6.2) Jarak Maintenance Pemeriksaan Setiap 40,000 km (25,000 miles) Penggantian Pertama 160,000 km (100,000 miles) Berikutnya Setiap 80,000 km (50,000 miles)

Sistem Intake dan Exhaust Keseluruhan Main Muffler Stainless Steel Exhaust Manifold Sub Muffler Link-less Type Throttle Body Resin Type Intake Manifold

Long Nozzle 4-hole Type Injector Sistem Bahan Bakar Keseluruhan Digunakan injector nozzle panjang dan quick connector Long Nozzle 4-hole Type Injector Pulsation Damper Pressure Regulator Quick Connector Quick connector for fuel pipe Fuel Filter Quick Connector

Sistem Bahan Bakar Injector Injector nozzle panjang digunakan untuk mengurangi emisi gas buang dengan mencegah bahan bakar menempel pada dinding intake Long nozzle type reach: 25.9 mm (1.02 in.) Normal type reach: 8.8 mm (0.35 in.) Approx. 25.9 mm Long Nozzle Type Normal Type* *Normal Type: 8.8 mm

Quick Turn Construction Fuel Cap Sistem Bahan Bakar Keseluruhan Quick Turn Construction Fuel Cap [Quick Connector] [Fuel Pump Module] Integrated type fuel pump assembly Fuel Tank Capacity: 55 liters Pump Motor Fuel Sender Gauge Steel Tank (55 L) Fuel Filter

Long Reach Type Spark Plug Sistem Pengapian Keseluruhan DIS menggunakan 4 ignition coils (4 silinder) Digunakan busi tipe panjang Long Reach Type Spark Plug Normal Type Spark Plug DIS

Center Electrode: Normal type Sistem Pengapian Busi Busi panjang memperbaiki sistem pendinginan pada kepala silinder (water jacket) Extended water Jacket Long Center Electrode: Normal type Long-reach Type Normal Type

Jangkauan [Ref.: Tipe Normal] Sistem Pengapian Busi Spesifikasi Busi Supplier DENSO K20HR-U11 Jangkauan [Ref.: Tipe Normal] Sekitar 26.5 mm [19.0 mm] Celah Busi 1.0 - 1.1 mm Jarak Penggantian Setiap 20,000 km atau 24 Bulan

Sistem Serpentine Belt Drive Keseluruhan Komponen asesories digerakan oleh serpentine belt, single V type 7-ribbed belt Power Steering Pump Pulley Idler Pulley No. 1 Alternator Pulley Water Pump Pulley Air Conditioner Compressor Pulley Automatic Tensioner Idler Pulley No. 2 Crankshaft Pulley

Sistem Serpentine Belt Drive Variasi Serpentine Belt [Jarak Pemeriksaan Serpentine Belt] berikutnya Setiap 20.000 km

Engine Control System Keseluruhan Air Flow Meter Ignition Coil with Igniter Non-contact Type Throttle Position Sensor Water Temp. Sensor Camshaft Position Sensor Flat Type Knock Sensor [Lainnya] 32-bit Engine ECU Non-contact Type Accelerator Pedal Position Sensor Crankshaft Position Sensor

Piezoelectric Element Engine Control System Flat type knock sensor Built-in open circuit detection resistor pada flat knock sensor Resistor If open circuit, application voltage will be increased to 5V. Piezoelectric Element 2.5 V 5 V Resistor NOTE: Saat open circuit, muncul DTC P0325 (baru)

Service Point (Engine Control System) Flat type knock sensor Pasang knock sensor pada sudut tertentu (10°) Depan 10 10 To prevent the water accumulation in the connector

Engine Control System ETCS-i (Electronic Throttle Control System-intelligent) Link-less type ETCS-i, untuk pengontrolan throttle yang lebih baik (Non-linear control/Idle speed control) Throttle Position Sensor Accelerator Pedal Position Sensor Throttle Control Motor Engine ECU Ignition Coil Air Flow Meter Fuel Injector

Engine Control System ETCS-i No-contact type throttle position sensor Throttle Control Motor Reduction Gears Throttle Valve Throttle Position Sensor Hall IC is used and makes no contact construction for better durability Hall ICs Magnets

Reference (Engine Control System) ETCS-i 2 Hall ICs dan 2 magnets digunakan untuk throttle position sensor Hall ICs Magnets Throttle Valve

Engine Control System ETCS-i Throttle position sensor merubah densitas magnetic flux menjadi electric signal Magnet 5 5 VTA2 VTA2 VC VTA1 VTA VC Output Voltage (V) Output Voltage (V) ECM E2 VTA2 Service Point No inspection procedures for no-contact type throttle position sensor VTA1 VTA VTA2 E2 Hall IC Full Close Full Close Full Open Full Open Throttle Valve Opening Angle Throttle Valve Opening Angle Engine ECU

Engine Control System ETCS-i No-contact type Accelerator pedal position sensor Magnets Hall ICs Hall IC uses and makes no contact construction for better durability Accelerator Pedal Arm

Accelerator Pedal Depressed Angle Engine Control System ETCS-i Accelerator pedal position sensor merubah densitas magnetic flux menjadi electric signal VPA Magnets EPA 5 VPA2 VCPA Output Voltage (V) VPA2 Service Point No inspection procedures for no-contact type accelerator pedal position sensor VPA EPA2 Hall ICs Full Close Full Open VCP2 Accelerator Pedal Depressed Angle Engine ECU (ECM)

[Single Signal Failure] [Double Signal Failure] Engine Control System ETCS-i Fail-safe jika malafungsi pada accelerator pedal position sensor [Normal Condition] [Single Signal Failure] [Double Signal Failure] Accelerator Pedal Position Sensor Engine ECU Engine ECU Engine ECU Full Idle Idle Idle Throttle Position Sensor Throttle Control Motor

Engine Control System ETCS-i Fail-safe jika malafungsi pada throttle valve position sensor / motor / engine ECU / wire harness [Normal Condition] [Fail-safe] Accelerator Pedal Position Sensor Engine ECU Engine ECU If throttle valve position sensor is malfunctioning, engine ECU cuts off current to throttle control motor. Throttle valve returns to predetermined throttle valve position (approx. 6.5 deg) by force of return spring. Full Fixed (6.5) Idle Idle Throttle Position Sensor Throttle Control Motor

Engine Control System ETCS-i Fail-safe jika malafungsi pada throttle valve position sensor / motor / engine ECU / wire harness [Idling] [Full Acceleration] Engine ECU Engine ECU Retard 4 >> 2 Cylinder Normal 2 >> 4 Cylinder Then, required engine power is calculated by using ignition timing and accelerator pedal position. Engine is controlled by intermittent fuel-cut. If accelerator pedal is depressed firmly and slowly, vehicle can be driven at minimum speed. If accelerator pedal is depressed quickly, vehicle may speed up and slow down erratically. Idle Fixed Idle Fixed

Engine Control System VVT-i (Variable Valve Timing-intelligent) System VVT-i system di rancang untuk mengontrol intake camshaft sehingga menghasilkan valve timing yang sesuai dengan kondisi mesin Camshaft Timing Oil Control Valve VVT-i Controller Throttle Position Sensor Water Temp. Sensor Camshaft Position Sensor Engine ECU Air Flow Meter Crankshaft Position Sensor

Vane (Fixed on Intake Camshaft) Engine Control System VVT-i System Controller terdiri dari housing yang digerakkan timing chain dan vane yang bersatu dengan intake camshaft Sprocket Intake Camshaft Housing Lock Pin Timing Rotor Vane (Fixed on Intake Camshaft) [In Operation] [At a Stop] Oil Pressure

To VVT-i Controller (Advanced Side) (Retard Side) Engine Control System VVT-i System Camshaft timing oil control valve mengontrol posisi spool valve sesuai dengan duty control dari ECU mesin To VVT-i Controller (Advanced Side) (Retard Side) Engine ECU Spool Valve Drain Plunger Oil Pressure Coil

Fitur Mesin 2TR-FE Spesifikasi Mesin 2TR-FE Model 1TR-FE 2TR-FE Jumlah silinder & susunan 4-cylinder, In-line  Mekanisme Katup 16-valve, DOHC with VVT-i, Chain Drive Displacement [cm3 (cu. in.)] 1,998 (121.9) 2,694 (164.4) Bore x Stroke [mm (in.)] 86.0 x 86.0 (3.39 x 3.39) 95.0 x 95.0 (3.74 x 3.74) Rasio Kompresi 9.8 : 1 Maximum Output SAE-NET [kW / rpm] 100 / 5,600 117 / 5,200 Maximum Torque SAE-NET [N·m / rpm] 182 / 4,000 242 / 3,800 Valve Timing Intake Buka 0  45 BTDC Tutup 64  19 ABDC Exhaust 44 BBDC 8 ATDC Fuel Octane Rating 91 atau lebih Tailpipe Emission Regulation  EURO II Oil Viscosity / Oil Grade 5W-30 / API SJ, SL, EC atau ILSAC Mesin 2TR-FE will be introduced in December 2004 [Mesin 2TR-FE Other Spesifikasi] Combustion Chamber: Pentroof Type Manifolds: Cross-flow Sistem Bahan Bakar: EFI Sistem Pengapian: DIS Firing Order: 1-3-4-2 Fuel: Unleaded Gasoline

Perbedaan Utama dari Mesin 1TR-FE Fitur Mesin 2TR-FE Perbedaan Utama dari Mesin 1TR-FE 1TR-FE 2TR-FE Balance shaft  2 balance shafts TWC with Fuel Tank Steel Resin Injector Long nozzle 4-hole type Long nozzle 12-hole type Starter P1.0 PS1.6 A/F, O2 Sensor Planar type O2 with heater x 1

Engine Control System Fuel Pump Control Signal peledakan airbag dari airbag sensor assembly dideteksi oleh ECU mesin, lalu meng-OFF circuit opening relay Ignition Switch EFI Relay Circuit Opening Relay Front Airbag Sensors (LH or RH) Airbag Sensor Assembly GSW2 F/PS Engine ECU Airbag not deployed M Battery Voltage Airbag deployed Fuel Pump Motor Approx. 4 sec.

Fitur Lain Sistem Pengisian Segment Conductor type alternator yang kompak dan ringan Motor Starter Conventional planetary reduction type starter Tipe SE08 Rated Voltage / Output 12V / 80A Supplier DENSO Tipe P1.0 Rated Voltage / Output 12V / 1.0 kW Supplier DENSO